Idea Transcript
Product Installation Instructions
HVS-3-820S 8kV Class Splice for 3/C Extruded Dielectric (Poly/EPR) Power Cable: Metallic Tape, Wire Shield, or UniShieldâ Cable
UniShield is a registered trademark of Cablec Corporation. Raychem Corporation Electrical Products Group 300 Constitution Drive Menlo Park, CA 94025-1164
PII-53146, Rev AC DCR C23552 PCN 426977-000 Effective Date: June 1991
General Instructions Suggested Installation Equipment (not supplied with kit) • Cable preparation tools • Raychem P42 cable preparation kit or cable manufacturer approved solvent
• Clean, lint-free cloths • Non-conducting abrasive cloth, 120 grit or finer • Electrician's tape
• Connector(s) and installation tools • Raychem recommended torch • Solder and soldering iron
Recommended Raychem Torches Install heat-shrinkable cable accessories with a "clean burning" torch, i.e., a propane torch that does not deposit conductive contaminants on the product.
Clean burning torches include the Raychem FH-2609, FH-2629 (uses refillable propane cylinders) and FH-2616A1 (uses disposable cylinder).
Safety Instructions Warning: When installing electrical power system accessories, failure to follow applicable personal safety requirements and written installation instructions could result in fire or explosion and serious or fatal injuries.
To avoid risk of accidental fire or explosion when using gas torches, always check all connections for leaks before igniting the torch and follow the torch manufacturer's safety instructions.
Adjusting the Torch
To minimize any effect of fumes produced during installation, always provide good ventilation of confined work spaces.
Regulator Pressure
Adjust regulator and torch as required to provide an overall 12- inch bushy flame. The FH-2629 will be all blue, the
other torches will have a 3- to 4-inch yellow tip. Use the yellow tip for shrinking.
FH-2616A1 FH-2609 FH-2629
To determine if a tube has completely recovered, look for the following, especially on the back and underside of the tube:
Note: When installing multiple tubes, make sure that the surface of the last tube is still warm before positioning and shrinking the next tube. If installed tube has cooled, re-heat the entire surface.
Full pressure 5 psig 15 psig
General Shrinking Instructions • Apply outer 3- to 4-inch tip of the flame to heat-shrinkable material with a rapid brushing motion. • Keep flame moving to avoid scorching. • Unless otherwise instructed, start shrinking tube at center, working flame around all sides of the tube to apply uniform heat.
1. Uniform wall thickness. 2. Conformance to substrate. 3. No flat spots or chill marks. 4. Visible sealant flow if the tube is coated.
Installation Instructions 1. Product selection.
2. Check ground braid.
Check kit selection with cable diameter dimensions in Table 1.
Verify that ground braid(s) or bond wire have equivalent cross-section to cable metallic shield. Additional braid may be needed for LC shield, lead sheath cables, or if external grounding or shield interrupting is required.
*If using 5/8kV (115 mils) cable use 8kV selection. Table 1 Kit Dimensions in inches HVS-3-821S HVS-3-822S HVS-3-823S HVS-3-824S HVS-3-825S
5kV Nominal Cable Range
8kV Nominal Cable Range
Minimum Jacket Diameter
Insulation Diameter Range
Maximum Connector Dimensions Length Diameter
#6-2/0 AWG* 3/0-300 kcmil* 350-750 kcmil* 750-1500 kcmil*
#6-#2 AWG #1-4/0 AWG 250-350 kcmil 500-750 kcmil 750-1000 kcmil
0.90 1.30 1.30 1.55 1.55
0.35-0.65 0.55-0.90 0.80-1.25 1.00-1.60 1.30-2.25
3.0 4.25 6.0 8.0 8.0
0.50 0.75 1.10 1.45 1.85
#6-#2 AWG #1-4/0 AWG 250-350 kcmil 500-750 kcmil 750-1000 kcmil
23 33 33 39 39
9-17 14-23 20-32 25-41 33-57
76 108 152 203 203
13 19 28 37 47
Dimensions in millimeters HVS-3-821S #6-2/0 AWG* HVS-3-822S 3/0-300 kcmil* HVS-3-823S 350-750 kcmil* HVS-3-824S 750-1500 kcmil* HVS-3-825S
PII-53146, Rev AC DCR C23552
Raychem HVS-EG supplies ground braid, spring clamp and suggested modifications to make an external ground or shield interrupt.
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PCN 426977-000 Effective Date: June 1991
Installation Instructions 3. Prepare cables. Choose the cable type (Choice 13) and use the dimensions shown in Table 2 to prepare the cables. Table 2 Jacket Cutbacks A1
Kit
Metallic Shield Cutback/ Wire Pullback B
A2
Semi-con Cutback C
.
HVS-3-821S HVS-3-822S HVS-3-823S HVS-3-824S HVS-3-825S
20" 22-1/2" 26-1/2" 30-1/2" 32"
(508mm) (572mm) (673mm) (775mm) (813mm)
10" 11-1/2" 12-1/2" 15" 15-1/2"
(254mm) (292mm) (318mm) (381mm) (394mm)
6" 7" 8" 9-1/2" 10"
(150mm) (180mm) (200mm) (240mm) (250mm)
CHOICE 1
3-1/4" 4" 5" 6" 6"
CL A2
A1
If Metallic Tape Shield Cable
B Refer to Table 2 and prepare the cables as shown. Remove any fillers to the jacket cutback. Bend back the grounding conductors(s) over the jacket as shown. Go to Step 4, page 4.
B C
C
Grounding Conductor(s)
Grounding Conductor(s)
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CHOICE 2
CL A2
A1
If Drain Wire Shield Cable
B
Refer to Table 2 and prepare the cables as shown. Remove any fillers to the jacket cutback. Pull drain wires back to Dimension B and temporarily tape over ends as shown. Bend back the grounding conductors(s) over the jacket as shown. Go to Step 4, page 4.
(80mm) (100mm) (125mm) (150mm) (150mm)
B C
Grounding Conductor(s)
C
Grounding Conductor(s)
Tape over ends of drain wires
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CHOICE 3 CL If UniShield Cable Refer to Table 2 and prepare the cables as shown. Remove any fillers to the jacket cutback. Pull drain wires back to Dimension B and temporarily tape over ends as shown. Bend back the grounding conductors(s) over the jacket as shown. Go to Step 4, page 4.
A2
A1 B
B C
Grounding Conductor(s)
Tape over ends of drain wires
C
Grounding Conductor(s) 326
PII-53146, Rev AC DCR C23552
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PCN 426977-000 Effective Date: June 1991
Installation Instructions 4. Remove insulation.
Table 3
Refer to Table 3 and Figure 1; cutback insulation as shown.
Kit
Maximum Connector Dimensions Length Diameter
HVS-3-821S HVS-3-822S HVS-3-823S HVS-3-824S HVS-3-825S
3.0" 4.25" 6.0" 8.0" 8.0"
(76mm) (108mm) (152mm) (203mm) (203mm)
0.50" 0.75" 1.10" 1.45" 1.85"
(13mm) (19mm) (28mm) (37mm) (47mm)
Expansion Gap "X" 1/4" 1/4" 1/2" 1/2" 1/2"
(5mm) (5mm) (10mm) (10mm) (10mm)
Figure 1: Insulation Cutback Z "Z" Insulation Cutback
X
=
"X" Expansion Gap
+
"Y" 1/2 Length of Connector
Y 400
5. Abrade insulation.
Abrade Insulation
Abrade the insulation, if necessary, to remove imbedded semi-con and clean as shown.
Clean
Abrade Insulation
Clean
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6. Place tubes over phases. Black Red Dual Layer Tube
Place one black/red dual layer tube over each phase as shown. Protect tubes from end of conductor as they are placed over cable end.
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7. Install connector. After installation, deburr connector.
Insulation
Insulation Connector 329
PII-53146, Rev AC DCR C23552
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PCN 426977-000 Effective Date: June 1991
Installation Instructions 8. Apply SRM over connector. Clean
Complete Steps 8-11 working on one phase at a time. Clean connector area and insulation, as shown, using an oil-free solvent.
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Remove backing from one side of the long strip of Stress Relief Material (SRM). Roll the SRM and remaining backing strip into a convenient size. Remove the remaining backing strip and tightly wrap the SRM around the connector and exposed conductor. Be sure to fill the gaps and low spots around the connector.
Stretch SRM to 1/2 Original Width
Fill Gaps
Continue to wrap SRM onto the solvent cleaned insulation as shown.
1/4"" (5mm) Insulation Overlap
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1/4""(5mm) Insulation Overlap
Note: If connector diameter is larger than insulation diameter, apply two half-lapped layers of SRM over the entire connector. Discard any excess SRM (long strips).
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9. Apply SRM at semi-con cutback. Stretch SRM to 1/4"(5mm) wide
SRM
Remove backings from the short angle-cut piece of SRM. Place tip of SRM at semi-con cutback and tightly wrap to fill semi-con step. Overlap semi-con and insulation as shown. Taper SRM down to meet insulation. Note: If using UniShield cable, apply SRM as shown to fill conductive jacket step.
1/4" (5mm) Insulation Overlap
1/4"(5mm) Semi-con Overlap 333
10. Apply red sealant. Red Sealant
Remove the backing from the red sealant and place one complete wrap onto the cable semi-con butted against the SRM as shown.
Red Sealant
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11. Position tube over connection. Black/Red Dual Layer Tube
Center black/red dual layer tube over completed connector area. Repeat Steps 8-11 on the remaining phases. PII-53146, Rev AC DCR C23552
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PCN 426977-000 Effective Date: June 1991
Installation Instructions 12. Check position of tubes; shrink in place. Make sure each tube is centered over the connection area. Shrink all three tubes in place at the same time. Begin shrinking at center of tube (1), working torch with a smooth, brushing motion around the tube. After center portion shrinks, work torch as before toward one end (2), then to the opposite end (3). Apply sufficient heat to ensure softening of the SRM, indicated by a smooth surface profile.
2
1
3
Black/Red Dual Layer Tubes
Note: Do not point the flame directly at the cable semi-con layer.
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Note: If External Grounding or Shield Interrupting Refer to Raychem HVS-EG, "Guide for External Grounding and Shield Interrupting of Power Cable Splices" for modifications to these instructions. 13. Install ground. Choose the appropriate cable type (Choice 1-2) and follow the directions given. CHOICE 1 If Metallic Tape Shield Cable
Ground Braid Spring Clamp
(1) Flare one end of the ground braid and place it onto the metallic tape butted up to the installed splice tube. (2) Attach the braid to the shield by placing two wraps of the spring clamp over the braid. (3) Fold the braid back over the spring clamp wraps. Continue to wrap the remaining clamp over the braid. Tighten clamp by twisting it in the direction it is wrapped and secure with copper foil tape provided.
1
2
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(4) Lay the braid across the splice tube and onto the exposed tape shield on the other side. (5) Make two wraps of the clamp over the braid. (6) Fold the braid back toward the splice and finish wrapping the clamp. Tighten and secure. Cut off excess braid. Repeat Choice 1 for remaining phases. Discard connectors.
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5
6
Go to Step 14, page 7. PII-53146, Rev AC DCR C23552
338
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PCN 426977-000 Effective Date: June 1991
Installation Instructions CHOICE 2 If Drain Wire or UniShield Cable Pigtail the wires on each side. Crimp the ground braid onto one pigtail with the connector provided.
Ground Braid
Connector
Lay braids across splice tubes and attach to pigtail on the other side. Cut off excess braid and trim pigtailed wires. Repeat Choice 2 for remaining phases. Discard spring clamps and foil tape. Go to Step 14.
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14. Connect grounding conductor(s). Bend the grounding conductor(s) back over the tubes and splice with a suitable connector. Grounding Conductor(s)
Connector 340
15. Install the shielding mesh. Starting on the cable shields, wrap a half-lapped layer of the mesh around all three phases across the length of the the tubes and tie off on the shields at the other side of the splice.
8" Clean Jacket (200mm)
Abrade and solvent clean cable jackets as shown to provide an oilfree surface.
Clean Jacket
8" (200mm)
Shielding Mesh 341
16. Position wraparound sleeve. Metal Channel
Remove or tape over all sharp points to prevent puncture of wraparound sleeve. Remove backing from the wraparound sealing sleeve and center sleeve over aplice. Slide metal channel(s) onto the butted rails.
PII-53146, Rev AC DCR C23552
Black Wraparound Sleeve
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PCN 426977-000 Effective Date: June 1991
Installation Instructions 17. Install channel clip. If two channels are used, connect the channels with the short channel retention clip. Use pliers to install clip.
Channel Clip
1/4" min. (5mm)
1/4" min. (5mm)
Note: Channel(s) must overlap sleeve edge by 1/4" (5mm) minimum.
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18. Shrink the wraparound sleeve. Begin shrinking at the center and work toward each end. Post heat the entire sleeve (concentrating on metal channel area) for 30 seconds after completely shrunk. This completes the splice. Note: Allow to cool before moving or placing in service.
PII-53146, Rev AC DCR C23552, PCN 426977-000 Effective Date: June 1991
Adhesive Flow (both ends)
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ã1991 Raychem Corporation Printed USA 6/91 (E7708)
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